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Genie S-60 S-65 S-60 HC S-60 Trax S-65 Trax Service Manual 139188 – PDF
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Description
Genie S-60 S-65 S-60 HC S-60 Trax S-65 Trax Service Manual 139188 – PDF DOWNLOAD
Language : English
Pages : 323
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-60 S-65 S-60 HC S-60 Trax S-65 Trax Service Manual 139188 – PDF DOWNLOAD
Cover........................................................................................................................................... 1 Introduction.................................................................................................................................... 2 Revision History................................................................................................................................ 3 Serial Number Legend............................................................................................................................ 5 Safety Rules.................................................................................................................................... 6 Table of Contents............................................................................................................................... 8 Specifications.................................................................................................................................. 19 Machine Specifications...................................................................................................................... 19 Performance Specifications.................................................................................................................. 20 Hydraulic Specifications.................................................................................................................... 21 Manifold Component Specifications........................................................................................................... 22 Ford DSG-423 EFI Engine..................................................................................................................... 23 Deutz F3L 2011 / Deutz D2011L03i Engine..................................................................................................... 24 Perkins 404-22 Engine....................................................................................................................... 26 Machine Torque Specifications............................................................................................................... 27 TRAX Torque Specifications.................................................................................................................. 28 Hydraulic Hose and Fitting Torque Specifications............................................................................................ 29 SAE and Metric Fastener Torque Chart........................................................................................................ 30 Scheduled Maintenance Procedures................................................................................................................ 31 Pre-Delivery Preparation.................................................................................................................... 33 Maintenance Inspection Report............................................................................................................... 35 Checklist A Procedures...................................................................................................................... 37 A-1 Inspect the Manuals and Decals...................................................................................................... 37 A-2 Perform Pre-operation Inspection.................................................................................................... 38 A-3 Perform Function Tests.............................................................................................................. 38 A-4 Perform Engine Maintenance.......................................................................................................... 39 A-5 Check the High Pressure Hydraulic Filter Condition Indicator........................................................................ 39 A-6 Test the Oscillate Axle (if equipped)............................................................................................... 40 A-7 Inspect the Track Components and Fastener Torque, S-60 TRAX and S-65 TRAX........................................................... 40 A-8 Perform 30 Day Service.............................................................................................................. 41 A-9 Check the Track Tension, S-60 TRAX and S-65 TRAX.................................................................................... 41 A-10 Perform Engine Maintenance - Ford and Perkins Models............................................................................... 43 A-11 Inspect the Fuel Filter/Water Separator - Diesel Models............................................................................ 43 A-12 Check and Adjust the Engine RPM - Perkins Models................................................................................... 45 A-13 Grease the Turntable Rotation Bearing and Rotate Gear.............................................................................. 46 A-14 Replace the Drive Hub Oil.......................................................................................................... 47 A-15 Perform Engine Maintenance - Ford Models........................................................................................... 49 A-16 Perform Engine Maintenance - Perkins Models........................................................................................ 49 Checklist B Procedures...................................................................................................................... 50 B-1 Inspect the Battery................................................................................................................. 50 B-2 Inpect the Electrical Wiring........................................................................................................ 51 B-3 Check the Exhaust System............................................................................................................ 52 B-4 Inspect the Engine Air Filter - Ford, Deutz and Perkins Models...................................................................... 53 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models................................................................................ 53 B-6 Inspect the Tires, Wheels and Lug Nut Torque, S-60, S-65 and S-60 HC................................................................ 54 B-7 Confirm the Proper Brake Configuration.............................................................................................. 55 B-8 Check the Drive Hub Oil Level and Fastener Torque................................................................................... 55 B-9 Check and Adjust the Engine RPM - Ford and Deutz Models............................................................................. 58 B-10 Test the Ground Control Override................................................................................................... 59 B-11 Check the Oscillate Directional Valve Linkage...................................................................................... 59 B-12 Test the Platform Self-leveling.................................................................................................... 60 B-13 Test the Engine Idle Select........................................................................................................ 60 B-14 Test the Fuel Select Operation - Ford Models....................................................................................... 61 B-15 Test the Drive Brakes.............................................................................................................. 62 B-16 Test the Drive Speed - Stowed Position............................................................................................. 62 B-17 Test the Drive Speed - Raised or Extended Position................................................................................. 63 B-18 Test the Alarm Package - Optional Equipment........................................................................................ 64 B-19 Perform Hydraulic Oil Analysis..................................................................................................... 65 B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems............................................................................ 65 B-21 Replace the Fuel Filter Element - Perkins Models................................................................................... 66 B-22 Inspect the Boom Extend/Retract cables............................................................................................. 68 B-23 Perform Engine Maintenance - Deutz Models.......................................................................................... 69 B-24 Perform Engine Maintenance - Ford Models........................................................................................... 70 B-25 Replace the Engine Air Filter Element - Ford Models................................................................................ 70 B-26 Perform Engine Maintenance - Perkins Models........................................................................................ 71 Checklist C Procedures...................................................................................................................... 72 C-1 Perform Engine Maintenance - Deutz Models........................................................................................... 72 C-2 Grease the Platform Overload Mechanism (if equipped), S-60, S-65, S-60 TRAX and S-65 TRAX........................................... 72 C-3 Test the Platform Overload System (if equipped), S-60, S-65, S-60 TRAX and S-65 TRAX................................................ 73 C-4 Test the Platform Load Sense System, S-60 HC........................................................................................ 76 C-5 Replace the Fuel Filter/Water Separator - Perkins Models............................................................................ 78 C-6 Replace the Engine Air Filter Element - Deutz and Perkins Models.................................................................... 80 C-7 Perform Engine Maintenance - Perkins Models......................................................................................... 80 C-8 Perform Engine Maintenance - Ford Models............................................................................................ 81 Checklist D Procedures...................................................................................................................... 82 D-1 Check the Boom Wear Pads............................................................................................................ 82 D-2 Check the Turntable Rotation Bearing Bolts.......................................................................................... 83 D-3 Inspect for Turntable Bearing Wear.................................................................................................. 84 D-4 Replace the Drive Hub Oil........................................................................................................... 85 D-5 Check the Free-wheel Configuration.................................................................................................. 87 D-6 Replace the Hydraulic Filters....................................................................................................... 89 D-7 Perform Engine Maintenance - Deutz Models........................................................................................... 91 Checklist E Procedures...................................................................................................................... 92 E-1 Test or Replace the Hydraulic Oil................................................................................................... 92 E-2 Perform Engine Maintenance - Deutz Models........................................................................................... 94 E-3 Perform Engine Maintenance - Deutz Models........................................................................................... 94 E-4 Replace the Boom Extend/Retract Cables.............................................................................................. 95 Repair Procedures............................................................................................................................... 97 Platform Controls........................................................................................................................... 98 1-1 ALC-500 Circuit Board............................................................................................................... 98 1-2 Joysticks........................................................................................................................... 99 Platform Components.........................................................................................................................104 2-1 Platform Leveling Slave Cylinder....................................................................................................104 2-2 Platform Rotator....................................................................................................................105 2-3 Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if equipped).........................................................107 2-4 Platform Load Sense System, S-60 HC.................................................................................................109 Jib Boom Components, S-65 and S-65 TRAX.....................................................................................................113 3-1 Jib Boom............................................................................................................................113 3-2 Jib Boom Lift Cylinder..............................................................................................................114 Boom Components.............................................................................................................................115 4-1 Cable Track.........................................................................................................................115 Boom Components.........................................................................................................................119 4-2 Boom................................................................................................................................120 4-3 Boom Lift Cylinder..................................................................................................................123 4-4 Boom Extension Cylinder.............................................................................................................124 4-5 Boom Extend/Retract Cables..........................................................................................................127 4-6 Platform Leveling Master Cylinder...................................................................................................130 Engines.....................................................................................................................................131 5-1 RPM Adjustment - Perkins Models.....................................................................................................131 5-2 RPM Adjustments - Ford and Deutz Models.............................................................................................131 5-3 Flex Plate..........................................................................................................................131 5-4 Engine Fault Codes - Ford Models....................................................................................................136 Hydraulic Pumps.............................................................................................................................137 6-1 Function Pump.......................................................................................................................137 6-2 Drive Pump..........................................................................................................................138 Manifolds...................................................................................................................................141 7-1 Function Manifold Components........................................................................................................141 7-2 Valve Adjustments - Function Manifold...............................................................................................145 7-3 Jib Boom / Platform Rotate Manifold Components......................................................................................146 7-4 Brake/Two-speed Manifold Components.................................................................................................147 7-5 Turntable Rotation Manifold Components..............................................................................................148 7-6 Oscillate Directional Valve Components..............................................................................................149 7-7 Valve Adjustments - Oscillate Relief Valve..........................................................................................151 7-8 Drive Oil Diverter Manifold (welder option).........................................................................................152 7-9 Traction Manifold Components, 2WD...................................................................................................153 7-10 Valve Adjustments, 2WD Traction Manifold...........................................................................................155 7-11 Traction Manifold Components, 4WD..................................................................................................157 7-12 Valve Adjustments, 4WD Traction Manifold...........................................................................................159 7-13 Valve Coils........................................................................................................................160 Turntable Rotation Components...............................................................................................................162 8-1 Turntable Rotation Assembly.........................................................................................................162 Axle Components.............................................................................................................................164 9-1 Oscillating Axle Cylinders..........................................................................................................164 Track Components............................................................................................................................165 10-1 Track Assembly, S-60 TRAX and S-65 TRAX............................................................................................165 Fault Codes.....................................................................................................................................169 Fault Codes - Control System................................................................................................................170 Fault Codes - Ford DSG-423 EFI Engine.......................................................................................................174 Fault Codes - Platform Load Sense System, S-60 HC...........................................................................................178 Schematics......................................................................................................................................187 Electrical Symbols Legend...................................................................................................................188 Hydraulic Symbols Legend....................................................................................................................189 Ford Engine Relay Layout....................................................................................................................190 Limit Switch Location Legend................................................................................................................191 Electrical Schematic, S-60 HC (before serial number 19039)..................................................................................194 Chassis Wiring Diagram, S-60 HC (before serial number 19039)................................................................................195 Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (before serial number 19039)......................................................198 Platform Control Box Wiring Diagram, S-60 HC (before serial number 19039)...................................................................199 Electrical Schematic, S-60 HC (after serial number 19038)...................................................................................202 Chassis Wiring Diagram, S-60 HC (after serial number 19038).................................................................................203 Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (after serial number 19038).......................................................206 Platform Control Box Wiring Diagram, S-60 HC (after serial number 19038)....................................................................207 Ford DSG-423 EFI Engine Harness.............................................................................................................209 Electrical Schematic, S-60 and S-60 TRAX, Ford DSG-423 EFI Models...........................................................................212 Ground Control Box Terminal Strip Wiring Diagram, S-60 and S-60 TRAX, Ford DSG-423 EFI Models...............................................216 Ground Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, Ford DSG-423 EFI Models.................................................217 Platform Control Box Wiring Diagram, S-60 and S-60 TRAX, Ford DSG-423 EFI Models............................................................220 Platform Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, Ford DSG-423 EFI Models...............................................221 Electrical Schematic, S-65 and S-65 TRAX, Ford DSG-423 EFI Models...........................................................................224 Ground Control Box Terminal Strip Wiring Diagram, S-65 and S-65 TRAX, Ford DSG-423 EFI Models...............................................228 Ground Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Ford DSG-423 EFI Models.................................................229 Platform Control Box Wiring Diagram, S-65 and S-65 TRAX, Ford DSG-423 EFI Models (before serial number 16734)...............................232 Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Ford DSG-423 EFI Models (before serial number 16734)..................233 Platform Control Box Wiring Diagram, S-65 and S-65 TRAX, Ford DSG-423 EFI Models (after serial number 16733)................................236 Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Ford DSG-423 EFI Models (after serial number 16733)...................237 Electrical Schematic, S-60 and S-60 TRAX, Deutz F3L 2011/D2011Lo3i Models...................................................................240 Electrical Schematic, S-60 and S-60 TRAX, CE Models, Deutz F3L 2011/D2011Lo3i Models........................................................244 Ground Control Box Terminal Strip Wiring Diagram, S-60 and S-60 TRAX, Deutz F3L 2011/Deutz D2011L03i Models.................................248 Ground Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, Deutz F3L 2011/Deutz D2011L03i Models...................................249 Ground Control Box Terminal Strip Wiring Diagram, S-60 and S-60 TRAX, CE Models, Deutz F3L 2011/Deutz D2011L03i Models......................252 Ground Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, CE Models, Deutz F3L 2011/Deutz D2011L03i Models........................253 Platform Control Box Wiring Diagram, S-60 and S-60 TRAX, Deutz F3L 2011/Deutz D2011L03i Models..............................................256 Platform Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, Deutz F3L 2011/Deutz D2011L03i Models.................................257 Electrical Schematic, S-65 and S-65 TRAX, Deutz F3L 2011/Deutz D2011L03i Models.............................................................260 Electrical Schematic, S-65 and S-65 TRAX, CE Models, Deutz F3L 2011/Deutz D2011L03i Models..................................................264 Ground Control Box Terminal Strip Wiring Diagram, S-65 and S-65 TRAX, Deutz F3L 2011/Deutz D2011L03i Models.................................268 Ground Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Deutz F3L 2011/Deutz D2011L03i Models...................................269 Ground Control Box Terminal Strip Wiring Diagram, S-65 and S-65 TRAX, CE Models, Deutz F3L 2011/Deutz D2011L03i Models......................272 Ground Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, CE Models, Deutz F3L 2011/Deutz D2011L03i Models........................273 Platform Control Box Wiring Diagram, S-65 and S-65 TRAX, Deutz F3L 2011/Deutz D2011L03i Models (before serial number 16734).................276 Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Deutz F3L 2011/Deutz D2011L03i Models (before serial number 16734)....277 Platform Control Box Wiring Diagram, S-65 and S-65 TRAX, Deutz F3L 2011 Models (after serial number 16733)..................................280 Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Deutz F3L 2011/Deutz D2011L03i Models (after serial number 16733).....281 Electrical Schematic, S-60 and S-60 TRAX, Perkins 404-22 Models.............................................................................284 Ground Control Box Terminal Strip Wiring Diagram, S-60 and S-60 TRAX, Perkins 404-22 Models.................................................288 Ground Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, Perkins 404-22 Models...................................................289 Platform Control Box Wiring Diagram, S-60 and S-60 TRAX, Perkins 404-22 Models..............................................................292 Platform Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX, Perkins 404-22 Models.................................................293 Electrical Schematic, S-65 and S-65 TRAX, Perkins 404-22 Models.............................................................................296 Ground Control Box Terminal Strip Wiring Diagram, S-65 and S-65 TRAX, Perkins 404-22 Models.................................................300 Ground Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Perkins 404-22 Models...................................................301 Platform Control Box Wiring Diagram, S-65 and S-65 TRAX, Perkins 404-22 Models (before serial number 16734).................................304 Platform Control Box Switch Panel Wiring Diagram (before serial number 16734)...............................................................305 Platform Control Box Wiring Diagram, S-65 and S-65 TRAX, Perkins 404-22 Models (after serial number 16733)..................................308 Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX, Perkins 404-22 Models (after serial number 16733).....................309 Belt Driven Generator Wiring Diagram........................................................................................................311 12kW Hydraulic Generator Option Wiring Diagram..............................................................................................314 Hydraulic Schematic, 12kW Hydraulic Generator Option (before serial number 19413)...........................................................315 Hydraulic Schematic, 12kW Hydraulic Generator Option (after serial number 19414)............................................................317 Hydraulic Schematic, 2WD Models.............................................................................................................319 Hydraulic Schematic, 4WD Models.............................................................................................................321 Back Cover......................................................................................................................................323 Return to Index................................................................................................................................. 0
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